How to Determine Critical Control Points (CCPs) and Why They’re Vital for Food Safety

How to Determine Critical Control Points (CCPs) and Why They’re Vital for Food Safety

Every food business — whether it’s a small bakery or a large dairy plant — works hard to keep products safe.
But ensuring food safety isn’t about luck; it’s about control.

That’s where the concept of Critical Control Points (CCPs) comes in.
Part of the HACCP (Hazard Analysis and Critical Control Points) system, CCPs help food companies identify the exact stages in production where problems can occur — and control them before they cause harm.

What Are Critical Control Points (CCPs)?

A Critical Control Point is a step in your process where control can be applied to prevent, eliminate, or reduce a food safety hazard to an acceptable level.

Think of CCPs as “checkpoints” — the places in your production line where you must pay extra attention to ensure safety.

For example:

• Pasteurization in milk production is a CCP because it destroys harmful microorganisms.
• Metal detection in packaged snacks is a CCP because it prevents physical contamination.

If these points are not properly monitored, the safety of the entire batch can be compromised.

How to Determine CCPs — Step by Step

Determining CCPs isn’t about guessing — it’s a structured process. Here’s how it’s done:

1️⃣ Conduct a Complete Hazard Analysis

Before identifying CCPs, list all possible hazards in your process — biological (like bacteria), chemical (like cleaning residues), or physical (like glass or metal pieces).

2️⃣ Map Your Entire Process

Draw a process flow diagram — from receiving raw materials to dispatching the finished product. This helps visualize where hazards could occur.

3️⃣ Use a CCP Decision Tree

A CCP decision tree helps you logically decide if a step is a CCP.
It includes questions like:

• Can a hazard be controlled at this step?
• Is there a subsequent step that will eliminate the hazard?
  If the answer is “no,” this step is likely a CCP.

4️⃣ Set Critical Limits

Once CCPs are identified, define the limits within which safety is maintained.
For example:

• Cooking temperature: Minimum 75°C for chicken to destroy pathogens.
• Metal detector sensitivity: Must detect 2.0 mm ferrous contaminants.

5️⃣ Implement Monitoring and Corrective Actions

Establish how often CCPs will be checked and what to do if limits are not met.
Example: If temperature drops below the safe limit, stop production and isolate the batch.

How to Eliminate or Control CCPs

You can’t always “remove” a CCP, but you can control or eliminate the hazard it represents by taking preventive measures such as:

• ✅ Regular Equipment Maintenance: Keep machines calibrated — faulty thermometers or detectors can cause missed hazards.
• ✅ Employee Training: Staff should understand why a CCP is important and how to monitor it.
• ✅ Supplier Control: Raw materials must be tested for quality before they enter your system.
• ✅ Sanitation Practices: Reduce microbial risks through proper cleaning and disinfection routines.
• ✅ Record Keeping: Documentation ensures traceability and accountability in case of issues.

Real-Life Examples of CCPs in Food Industry

Example 1 – Dairy Plant:
In a milk processing plant, pasteurization is identified as a CCP. The critical limit is heating milk to at least 72°C for 15 seconds.
If the temperature drops below this, harmful bacteria may survive — so the system automatically diverts that batch for reprocessing.

Example 2 – Ready-to-Eat Food Manufacturer:
A company producing frozen meals identified the freezing step as a CCP.
They monitor freezer temperature continuously — keeping it below –18°C to prevent microbial growth and preserve product quality.

Example 3 – Biscuit Factory:
The metal detection stage was found to be a CCP.
After one incident where the detector failed, the company added daily calibration checks and verification records — eliminating future risks.

Why Eliminating or Controlling CCPs Is So Important

• 🛡️ Protects Consumers: Controlling CCPs ensures that unsafe food never reaches the market.
• 💼 Prevents Recalls: Avoiding contamination and hazards saves companies from costly recalls and brand damage.
• 🌎 Ensures Legal Compliance: Regulatory bodies and certification schemes like ISO 22000, FSSAI, and BRC require documented CCP management.
• 🚀 Builds Customer Trust: Consumers associate safe food with reliable brands — and CCP control is the backbone of that trust.
• 📈 Improves Process Efficiency: Monitoring CCPs often highlights process inefficiencies, helping teams improve productivity.

How BIGISO Software Simplifies CCP Monitoring

Tracking CCPs manually can be overwhelming.
BIGISO Cloud Software helps automate this process with:
✅ Real-time CCP monitoring dashboards
✅ Alerts for deviations and corrective actions
✅ Digital record keeping for audits
✅ Trend analysis for continuous improvement

With BIGISO, food safety isn’t just compliant — it’s consistent, transparent, and easy to manage.

Final Thoughts

Identifying and managing Critical Control Points is like installing safety locks on every door that leads to risk.
It’s not just about passing an audit — it’s about protecting your brand, your customers, and the reputation you’ve worked hard to build.

When every employee understands the “why” behind CCPs, food safety becomes part of the culture — not just a checklist.